Troubleshooting

When diagnosing a specific problem, organized troubleshooting is a must. The complexity of a modern automobile demands that you approach any problem in a logical, organized manner. There are certain troubleshooting techniques that are standard:

Establish when the problem occurs. Does the problem appear only under certain conditions- Were there any noises, odors, or other unusual symptoms-

Isolate the problem area. To do this, make some simple tests and observations; then eliminate the systems that are working properly. Check for obvious problems such as broken wires, dirty connections or split/disconnected vacuum hoses. Always check the obvious before assuming something complicated is the cause.

Test for problems systematically to determine the cause once the problem area is isolated. Are all the components functioning properly- Is there power going to electrical switches and motors- Is there vacuum at vacuum switches and/or actuators- Is there a mechanical problem such as bent linkage or loose mounting screws- Performing careful, systematic checks will often turn up most causes on the first inspection without wasting time checking components that have little or no relationship to the problem.

Test all repairs after the work is done to make sure that the problem is fixed. Some causes can be traced to more than one component, so a careful verification of repair work is important in order to pick up additional malfunctions that may cause a problem to reappear or a different problem to arise. A blown fuse, for example, is a simple problem that may require more than another fuse to repair. If you don't look for a problem that caused a fuse to blow, a shorted wire (for example) may go undetected.

Experience has shown that most problems tend to be the result of a fairly simple and obvious cause, such as loose or corroded connectors or air leaks in the intake system. This makes careful inspection of components during testing essential to quick and accurate troubleshooting.

BASIC TROUBLESHOOTING THEORY

Electrical problems generally fall into one of three areas:

The component that is not functioning is not receiving current.

The component itself is not functioning.

The component is not properly grounded.

Problems that fall into the first category are by far the most complicated. It is the current supply system to the component which contains all the switches, relay, fuses, etc.

The electrical system can be checked with a test light and a jumper wire. A test light is a device that looks like a pointed screwdriver with a wire attached to it. It has a light bulb in its handle. A jumper wire is a piece of insulated wire with an alligator clip attached to each end.

If a light bulb is not working, you must follow a systematic plan to determine which of the three causes is the villain.

Turn on the switch that controls the inoperable bulb.

Disconnect the power supply wire from the bulb.

Attach the ground wire to the test light to a good metal ground.

Touch the probe end of the test light to the end of the power supply wire that was disconnected from the bulb. If the bulb is receiving current, the test light will go on.

If the bulb is one which works only when the ignition key is turned on (turn signal), make sure the key is turned on.

If the test light does not go on, then the problem is in the circuit between the battery and the bulb. As mentioned before, this includes all the switches, fuses, and relays in the system. Turn to a wiring diagram and find the bulb on the diagram. Follow the wire that runs back to the battery. The problem is an open circuit between the battery and the bulb. If the fuse is blown and, when replaced, immediately blows again, there is a short circuit in the system which must be located and repaired. If there is a switch in the system, bypass it with a jumper wire. This is done by connecting one end of the jumper wire to the power supply wire into the switch and the other end of the jumper wire to the wire coming out of the switch. If the test light illuminates with the jumper wire installed, the switch or whatever was bypassed is defective.

Never substitute the jumper wire for the bulb, as the bulb is the component required to use the power from the power source.

If the bulb in the test light goes on, then the current is getting to the bulb that is not working in the car. This eliminates the first of the three possible causes. Connect the power supply wire and connect a jumper wire from the bulb to a good metal ground. Do this with the switch which controls the bulb works with jumper wire installed, then it has a bad ground. This is usually caused by the metal area on which the bulb mounts to the vehicle being coated with some type of foreign matter.

If neither test located the source of the trouble, then the light bulb itself is defective.

The above test procedure can be applied to any of the components of the chassis electrical system by substituting the component that is not working for the light bulb. Remember that for any electrical system to work, all connections must be clean and tight.

TEST EQUIPMENT

Pinpointing the exact cause of trouble in an electrical system can sometimes only be accomplished by the use of special test equipment. The following describes different types of commonly used test equipment and explains how to use them in diagnosis. In addition to the information covered below, the tool manufacturer's instructions guidelet (provided with the tester) should be read and clearly understood before attempting any test procedures.

Jumper Wires

Fig. Fig. 1 Example of using a jumper wire to bypass a switch during a diagnostic test

Fig. Fig. 2 Checking for a bad ground connection with a jumper wire

Jumper wires are simple, yet extremely valuable, pieces of test equipment. They are basically test wires which are used to bypass sections of a circuit. The simplest type of jumper wire is a length of multi-strand wire with an alligator clip at each end. Jumper wires are usually fabricated from lengths of standard automotive wire and whatever type of connector (alligator clip, spade connector or pin connector) that is required for the particular vehicle being tested. The well equipped tool box will have several different styles of jumper wires in several different lengths. Some jumper wires are made with three or more terminals coming from a common splice for special purpose testing. In cramped, hard-to-reach areas it is advisable to have insulated boots over the jumper wire terminals in order to prevent accidental grounding, sparks, and possible fire, especially when testing fuel system components.

Jumper wires are used primarily to locate open electrical circuits, on either the ground (-) side of the circuit or on the hot (+) side. If an electrical component fails to operate, connect the jumper wire between the component and a good ground. If the component operates only with the jumper installed, the ground circuit is open. If the ground circuit is good, but the component does not operate, the circuit between the power feed and component may be open. By moving the jumper wire successively back from the lamp toward the power source, you can isolate the area of the circuit where the open is located. When the component stops functioning, or the power is cut off, the open is in the segment of wire between the jumper and the point previously tested.

You can sometimes connect the jumper wire directly from the battery to the hot terminal of the component, but first make sure the component uses 12 volts in operation. Some electrical components, such as fuel injectors, are designed to operate on about 4 volts and running 12 volts directly to the injector terminals can cause damage.

By inserting an in-line fuse holder between a set of test leads, a fused jumper wire can be used for bypassing open circuits. Use a 5 amp fuse to provide protection against voltage spikes. When in doubt, use a voltmeter to check the voltage input to the component and measure how much voltage is normally being applied.

CAUTION

Never use jumpers made from wire that is of lighter gauge than that which is used in the circuit under test. If the jumper wire is of too small a gauge, it may overheat and possibly melt. Never use jumpers to bypass high resistance loads in a circuit. Bypassing resistances, in effect, creates a short circuit. This may, in turn, cause damage and fire. Jumper wires should only be used to bypass lengths of wire.

Unpowered Test Lights

The 12 volt test light is used to check circuits and components while electrical current is flowing through them. It is used for voltage and ground tests. Twelve volt test lights come in different styles but all have three main parts; a ground clip, a probe, and a light. The most commonly used 12 volt test lights have pick-type probes. To use a 12 volt test light, connect the ground clip to a good ground and probe wherever necessary with the pick. The pick should be sharp so that it can be probed into tight spaces.

CAUTION

Do not use a test light to probe electronic ignition spark plug or coil wires. Never use a pick-type test light to probe wiring on computer controlled systems unless specifically instructed to do so. Any wire insulation that is pierced by the test light probe should be taped and sealed with silicone after testing.

Like the jumper wire, the 12 volt test light is used to isolate opens in circuits. But, whereas the jumper wire is used to bypass the open to operate the load, the 12 volt test light is used to locate the presence of voltage in a circuit. If the test light glows, you know that there is power up to that point; if the 12 volt test light does not glow when its probe is inserted into the wire or connector, you know that there is an open circuit (no power). Move the test light in successive steps back toward the power source until the light in the handle does glow. When it glows, the open is between the probe and point which was probed previously.

The test light does not detect that 12 volts (or any particular amount of voltage) is present; it only detects that some voltage is present. It is advisable before using the test light to touch its terminals across the battery posts to make sure the light is operating properly.

Self-Powered Test Lights

The self-powered test light usually contains a 1.5 volt penlight battery. One type of self-powered test light is similar in design to the 12 volt unit. This type has both the battery and the light in the handle, along with a pick-type probe tip. The second type has the light toward the open tip, so that the light illuminates the contact point. The self-powered test light is a dual purpose piece of test equipment. It can be used to test for either open or short circuits when power is isolated from the circuit (continuity test). A powered test light should not be used on any computer controlled system or component unless specifically instructed to do so. Many engine sensors can be destroyed by even this small amount of voltage applied directly to the terminals.

Voltmeters

A voltmeter is used to measure voltage at any point in a circuit, or to measure the voltage drop across any part of a circuit. It can also be used to check continuity in a wire or circuit by indicating current flow from one end to the other. Analog voltmeters usually have various scales on the meter dial and a selector switch to allow the selection of different voltages. The voltmeter has a positive and a negative lead. To avoid damage to the meter, always connect the negative lead to the negative (-) side of the circuit (to ground or nearest the ground side of the circuit) and connect the positive lead to the positive (+) side of the circuit (to the power source or the nearest power source). Note that the negative voltmeter lead will always be black and that the positive voltmeter will always be some color other than black (usually red).

Depending on how the voltmeter is connected into the circuit, it has several uses. A voltmeter can be connected either in parallel or in series with a circuit and it has a very high resistance to current flow. When connected in parallel, only a small amount of current will flow through the voltmeter current path; the rest will flow through the normal circuit current path and the circuit will work normally. When the voltmeter is connected in series with a circuit, only a small amount of current can flow through the circuit. The circuit will not work properly, but the voltmeter reading will show if the circuit is complete or not.

Ohmmeters

The ohmmeter is designed to read resistance (which is measured in ohms or omega ) in a circuit or component. Although there are several different styles of ohmmeters, all analog meters will usually have a selector switch which permits the measurement of different ranges of resistance (usually the selector switch allows the multiplication of the meter reading by 10, 100, 1000, and 10,000). A calibration knob allows the meter to be set at zero for accurate measurement. Since all ohmmeters are powered by an internal battery, the ohmmeter can be used as a self-powered test light. When the ohmmeter is connected, current from the ohmmeter flows through the circuit or component being tested. Since the ohmmeter's internal resistance and voltage are known values, the amount of current flow through the meter depends on the resistance of the circuit or component being tested.

The ohmmeter can be used to perform a continuity test for opens or shorts (either by observation of the meter needle or as a self-powered test light), and to read actual resistance in a circuit. It should be noted that the ohmmeter is used to check the resistance of a component or wire while there is no voltage applied to the circuit. Current flow from an outside voltage source (such as the vehicle battery) can damage the ohmmeter, so the circuit or component should be isolated from the vehicle electrical system before any testing is done. Since the ohmmeter uses its own voltage source, either lead can be connected to any test point.

When checking diodes or other solid state components, the ohmmeter leads can only be connected one way in order to measure current flow in a single direction. Make sure the positive (+) and negative (-) terminal connections are as described in the test procedures to verify the one-way diode operation.

In using the meter for making continuity checks, do not be concerned with the actual resistance readings. Zero resistance, or any ohm reading, indicates continuity in the circuit. Infinite resistance indicates an open in the circuit. A high resistance reading where there should be none indicates a problem in the circuit. Checks for short circuits are made in the same manner as checks for open circuits except that the circuit must be isolated from both power and normal ground. Infinite resistance indicates no continuity to ground, while zero resistance indicates a dead short to ground.

Ammeters

An ammeter measures the amount of current flowing through a circuit in units called amperes or amps. Amperes are units of electron flow which indicate how fast the electrons are flowing through the circuit. Since Ohms Law dictates that current flow in a circuit is equal to the circuit voltage divided by the total circuit resistance, increasing voltage also increases the current level (amps). Likewise, any decrease in resistance will increase the amount of amps in a circuit. At normal operating voltage, most circuits have a characteristic amount of amperes, called "current draw" which can be measured using an ammeter. By referring to a specified current draw rating, measuring the amperes, and comparing the two values, one can determine what is happening within the circuit to aid in diagnosis. An open circuit, for example, will not allow any current to flow so the ammeter reading will be zero. More current flows through a heavily loaded circuit or when the charging system is operating.

An ammeter is always connected in series with the circuit being tested. All of the current that normally flows through the circuit must also flow through the ammeter; if there is any other path for the current to follow, the ammeter reading will not be accurate. The ammeter itself has very little resistance to current flow and therefore will not affect the circuit, but it will measure current draw only when the circuit is closed and electricity is flowing. Excessive current draw can blow fuses and drain the battery, while a reduced current draw can cause motors to run slowly, lights to dim and other components to not operate properly. The ammeter can help diagnose these conditions by locating the cause of the high or low reading.

Multimeters

Different combinations of test meters can be built into a single unit designed for specific tests. Some of the more common combination test devices are known as Volt/Amp testers, Tach/Dwell meters, or Digital Multimeters. The Volt/Amp tester is used for charging system, starting system or battery tests and consists of a voltmeter, an ammeter and a variable resistance carbon pile. The voltmeter will usually have at least two ranges for use with 6, 12 and/or 24 volt systems. The ammeter also has more than one range for testing various levels of battery loads and starter current draw. The carbon pile can be adjusted to offer different amounts of resistance. The Volt/Amp tester has heavy leads to carry large amounts of current and many later models have an inductive ammeter pickup that clamps around the wire to simplify test connections. On some models, the ammeter also has a zero-center scale to allow testing of charging and starting systems without switching leads or polarity. A digital multimeter is a voltmeter, ammeter and ohmmeter combined in an instrument which gives a digital readout. These are often used when testing solid state circuits because of their high input impedance (usually 10 megohms or more).

The tach/dwell meter that combines a tachometer and a dwell (cam angle) meter is a specialized kind of voltmeter. The tachometer scale is marked to show engine speed in rpm and the dwell scale is marked to show degrees of distributor shaft rotation. In most electronic ignition systems, dwell is determined by the control unit, but the dwell meter can also be used to check the duty cycle (operation) of some electronic engine control systems. Some tach/dwell meters are powered by an internal battery, while others take their power from the vehicle battery in use. The battery powered testers usually require calibration (much like an ohmmeter) before testing.

TESTING

Open Circuits

To use the self-powered test light or a multimeter to check for open circuits, first isolate the circuit from the vehicle's 12 volt power source by disconnecting the battery or wiring harness connector. Connect the test light or ohmmeter ground clip to a good ground and probe sections of the circuit sequentially with the test light. (start from either end of the circuit). If the light is out/or there is infinite resistance, the open is between the probe and the circuit ground. If the light is on/or the meter shows continuity, the open is between the probe and end of the circuit toward the power source.

Short Circuits

By isolating the circuit both from power and from ground, and using a self-powered test light or multimeter, you can check for shorts to ground in the circuit. Isolate the circuit from power and ground. Connect the test light or ohmmeter ground clip to a good ground and probe any easy-to-reach test point in the circuit. If the light comes on or there is continuity, there is a short somewhere in the circuit. To isolate the short, probe a test point at either end of the isolated circuit (the light should be on/there should be continuity). Leave the test light probe engaged and open connectors, switches, remove parts, etc., sequentially, until the light goes out/continuity is broken. When the light goes out, the short is between the last circuit component opened and the previous circuit opened.

The battery in the test light and does not provide much current. A weak battery may not provide enough power to illuminate the test light even when a complete circuit is made (especially if there are high resistances in the circuit). Always make sure that the test battery is strong. To check the battery, briefly touch the ground clip to the probe; if the light glows brightly the battery is strong enough for testing. Never use a self-powered test light to perform checks for opens or shorts when power is applied to the electrical system under test. The 12 volt vehicle power will quickly burn out the light bulb in the test light.

Available Voltage Measurement

Set the voltmeter selector switch to the 20V position and connect the meter negative lead to the negative post of the battery. Connect the positive meter lead to the positive post of the battery and turn the ignition switch
ON
to provide a load. Read the voltage on the meter or digital display. A well charged battery should register over 12 volts. If the meter reads below 11.5 volts, the battery power may be insufficient to operate the electrical system properly. This test determines voltage available from the battery and should be the first step in any electrical trouble diagnosis procedure. Many electrical problems, especially on computer controlled systems, can be caused by a low state of charge in the battery. Excessive corrosion at the battery cable terminals can cause a poor contact that will prevent proper charging and full battery current flow.

Normal battery voltage is 12 volts when fully charged. When the battery is supplying current to one or more circuits it is said to be "under load." When everything is off the electrical system is under a "no-load" condition. A fully charged battery may show about 12.5 volts at no load; will drop to 12 volts under medium load; and will drop even lower under heavy load. If the battery is partially discharged the voltage decrease under heavy load may be excessive, even though the battery shows 12 volts or more at no load. When allowed to discharge further, the battery's available voltage under load will decrease more severely. For this reason, it is important that the battery be fully charged during all testing procedures to avoid errors in diagnosis and incorrect test results.

Voltage Drop

When current flows through a resistance, the voltage beyond the resistance is reduced (the larger the current, the greater the reduction in voltage). When no current is flowing, there is no voltage drop because there is no current flow. All points in the circuit which are connected to the power source are at the same voltage as the power source. The total voltage drop always equals the total source voltage. In a long circuit with many connectors, a series of small, unwanted voltage drops due to corrosion at the connectors can add up to a total loss of voltage which impairs the operation of the normal loads in the circuit. The maximum allowable voltage drop under load is critical, especially if there is more than one high resistance problem in a circuit because all voltage drops are cumulative. A small drop is normal due to the resistance of the conductors.

INDIRECT COMPUTATION OF VOLTAGE DROPS

Set the voltmeter selector switch to the 20 volt position.

Connect the meter negative lead to a good ground.

While operating the circuit, probe all loads in the circuit with the positive meter lead and observe the voltage readings. A drop should be noticed after the first load. But, there should be little or no voltage drop before the first load.

DIRECT MEASUREMENT OF VOLTAGE DROPS

Set the voltmeter switch to the 20 volt position.

Connect the voltmeter negative lead to the ground side of the load to be measured.

Connect the positive lead to the positive side of the resistance or load to be measured.

Read the voltage drop directly on the 20 volt scale.

Too high a voltage indicates too high a resistance. If, for example, a blower motor runs too slowly, you can determine if perhaps there is too high a resistance in the resistor pack. By taking voltage drop readings in all parts of the circuit, you can isolate the problem. Too low a voltage drop indicates too low a resistance. Take the blower motor for example again. If a blower motor runs too fast in the MED and/or LOW position, the problem might be isolated in the resistor pack by taking voltage drop readings in all parts of the circuit to locate a possibly shorted resistor.

HIGH RESISTANCE TESTING

Set the voltmeter selector switch to the 4 volt position.

Connect the voltmeter positive lead to the positive post of the battery.

Turn on the headlights and heater blower to provide a load.

Probe various points in the circuit with the negative voltmeter lead.

Read the voltage drop on the 4 volt scale. Some average maximum allowable voltage drops are:

FUSE PANEL: 0.7 volts

IGNITION SWITCH: 0.5 volts

HEADLIGHT SWITCH: 0.7 volts

IGNITION COIL (+): 0.5 volts

ANY OTHER LOAD: 1.3 volts

Voltage drops are all measured while a load is operating; without current flow, there will be no voltage drop.

Resistance Measurement

The batteries in an ohmmeter will weaken with age and temperature, so the ohmmeter must be calibrated or "zeroed" before taking measurements. To zero the meter, place the selector switch in its lowest range and touch the two ohmmeter leads together. Turn the calibration knob until the meter needle is exactly on zero.

All analog (needle) type ohmmeters must be zeroed before use, but some digital ohmmeter models are automatically calibrated when the switch is turned on. Self-calibrating digital ohmmeters do not have an adjusting knob, but its a good idea to check for a zero readout before use by touching the leads together. All computer controlled systems require the use of a digital ohmmeter with at least 10 megohms impedance for testing. Before any test procedures are attempted, make sure the ohmmeter used is compatible with the electrical system or damage to the on-board computer could result.

To measure resistance, first isolate the circuit from the vehicle power source by disconnecting the battery cables or the harness connector. Make sure the key is
OFF
when disconnecting any components or the battery. Where necessary, also isolate at least one side of the circuit to be checked in order to avoid reading parallel resistances. Parallel circuit resistances will always give a lower reading than the actual resistance of either of the branches. When measuring the resistance of parallel circuits, the total resistance will always be lower than the smallest resistance in the circuit. Connect the meter leads to both sides of the circuit (wire or component) and read the actual measured ohms on the meter scale. Make sure the selector switch is set to the proper ohm scale for the circuit being tested to avoid misreading the ohmmeter test value.

WARNING

Never use an ohmmeter with power applied to the circuit. Like the self-powered test light, the ohmmeter is designed to operate on its own power supply. The normal 12 volt automotive electrical system current could damage the meter!